US4725477A - Predecorated gypsum board - Google Patents

Predecorated gypsum board Download PDF

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Publication number
US4725477A
US4725477A US06/812,516 US81251685A US4725477A US 4725477 A US4725477 A US 4725477A US 81251685 A US81251685 A US 81251685A US 4725477 A US4725477 A US 4725477A
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United States
Prior art keywords
paper
base coat
gypsum wallboard
predecorated
defined
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Expired - Lifetime
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US06/812,516
Inventor
Donald R. Kole
Arthur E. Kennedy
George J. Bean, Jr.
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National Gypsum Properties LLC
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National Gypsum Co
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Publication date
Priority to US06/680,798 priority Critical patent/US4579610A/en
Application filed by National Gypsum Co filed Critical National Gypsum Co
Priority to US06/812,516 priority patent/US4725477A/en
Assigned to NATIONAL GYPSUM COMPANY reassignment NATIONAL GYPSUM COMPANY ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: KENNEDY, ARTHUR E., KOLE, DONALD R., BEAN, GEORGE J. JR.
Assigned to CITICORP INDUSTRIAL CREDIT INC. reassignment CITICORP INDUSTRIAL CREDIT INC. SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NATIONAL GYPSUM COMPANY
Assigned to NATIONAL GYUPSUM COMPANY reassignment NATIONAL GYUPSUM COMPANY RELEASED BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: CITICORP INDUSTRIAL CREDIT, INC.
Priority claimed from US07/100,803 external-priority patent/US5055323A/en
Publication of US4725477A publication Critical patent/US4725477A/en
Application granted granted Critical
Assigned to GENERAL ELECTRIC CAPITAL CORPORATION, A CORP. OF NY reassignment GENERAL ELECTRIC CAPITAL CORPORATION, A CORP. OF NY SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NATIONAL GYPSUM COMPANY
Assigned to NATIONAL GYPSUM COMPANY reassignment NATIONAL GYPSUM COMPANY PARTY RELEASING LIENS; SEE RECORDS FOR DETAILS. Assignors: GENERAL ELECTRIC CAPITAL CORPORATION, A NEW YORK CORPORATION
Assigned to NATIONAL GYPSUM COMPANY reassignment NATIONAL GYPSUM COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NATIONAL GYPSUM COMPANY, A DELAWARE CORPORATION, NOW NAMED ABESTOS CLAIMS MANAGEMENT CORPORATION
Assigned to GENERAL ELECTRIC CAPITAL CORPORATION reassignment GENERAL ELECTRIC CAPITAL CORPORATION LICENSE (SEE DOCUMENT FOR DETAILS). Assignors: NATIONAL GYPSUM COMPANY A CORP. OF DELAWARE
Assigned to NATIONAL GYPSUM COMPANY reassignment NATIONAL GYPSUM COMPANY ASSIGNMENT AND RELEASE, SATISFACTION AND DISCHARGE OF MORTGAGE OF PATENTS AND PATENT LICENSES Assignors: GENERAL ELECTRIC CAPITAL CORPORATION
Assigned to NATIONSBANK, N.A. (CAROLINAS) reassignment NATIONSBANK, N.A. (CAROLINAS) SECURITY AGREEMENT Assignors: NATIONAL GYPSUM COMPANY, A DE CORP.
Assigned to NATIONAL GYPSUM PROPERTIES LLC reassignment NATIONAL GYPSUM PROPERTIES LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NATIONAL GYPSUM COMPANY, A DELAWARE CORPORATION
Assigned to NATIONAL GYPSUM PROPERTIES, LLC, A CORPORATION OF DELAWARE reassignment NATIONAL GYPSUM PROPERTIES, LLC, A CORPORATION OF DELAWARE RELEASE OF SECURITY INTEREST Assignors: BANK OF AMERICA, N.A., AS ADMINISTRATIVE AGENT, FORMERLY NATIONSBANK, N.A. (CAROLINAS), A NATIONAL BANK
Assigned to BANK OF AMERICA, N.A. reassignment BANK OF AMERICA, N.A. SECURITY AGREEMENT Assignors: NATIONAL GYPSUM PROPERTIES, LLC
Anticipated expiration legal-status Critical
Assigned to NEW NGC, INC., D/B/A NATIONAL GYPSUM COMPANY, NATIONAL GYPSUM PROPERTIES, LLC reassignment NEW NGC, INC., D/B/A NATIONAL GYPSUM COMPANY RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: BANK OF AMERICA, N.A.
Application status is Expired - Lifetime legal-status Critical

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS, SLAG, OR MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M3/00Printing processes to produce particular kinds of printed work, e.g. patterns
    • B41M3/18Particular kinds of wallpapers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24893Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material
    • Y10T428/24901Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material including coloring matter
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24934Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including paper layer
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/27Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
    • Y10T428/273Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.] of coating
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/27Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
    • Y10T428/273Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.] of coating
    • Y10T428/277Cellulosic substrate
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31971Of carbohydrate
    • Y10T428/31993Of paper

Abstract

A predecorated gypsum wallboard and the method of manufacture wherein a protective base coat is applied on the face paper by a rotogravure printing of the protective coat with minute openings very closely spaced throughout the coating, as by printing the coat in the form of reasonably uniformly sized tiny dots with about 1000 to about 100,000 dots per square inch, a decorative coat is applied over the base coat, gypsum wallboard is formed with the coated surface of the paper on the outside face, and the newly formed wallboard, when hardened, is dried by heating and removing water from the gypsum core through the still porous coated paper.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application is a division of copending application, Ser. No. 06/680,798, filed Dec. 13, 1984, now U.S. Pat. No. 4,579,610.

This invention relates to predecorated gypsum wallboard face paper, to gypsum wallboard made therefrom and to the method of making the face paper and the gypsum wallboard.

BACKGROUND OF THE INVENTION

Gypsum wallboard is commonly used, in any of several different forms, in constructing interior walls and ceilings. In its most common form, a cream-colored face paper forms the wall exterior, the joints are covered by a setting or drying cementitious material, and the resultant monolithic wall is painted. The cream color of the face paper is provided by the choice of fibers used in the surface ply in its manufacture and/or dyes incorporated therein.

Other forms of gypsum board have been developed and marketed, with the alm of reducing the labor required in constructing, finishing and decorating the wall. These other forms generally involved substantial increases in the product cost, and met with little success unless they also incorporated a relatively maintenance-free surface, providing the justification for the substantial increase. In such cases, the increase in cost has generally been such that it was hard for consumers to justify except in large commercial structures, where subsequent maintenance costs are of substantial importance.

One problem that is faced in any attempt to provide a predecorated web of paper to be used in the subsequent manufacture of a paper-covered, gypsum-core wallboard is the necessity of providing a durable surface while maintaining sufficient porosity through the predecorated paper so that, after the gypsum and paper have been combined, the newly formed boards can be dried by high temperature removal of the excess water in the core through the predecorated face paper. Prior attempts to provide predecorated face papers for use in making gypsum board generally involved a coating which decreased porosity excessively. One prior solution to this problem, described in Veschuroff U.S. Pat. No. 3,694,298, suggests embossing the paper after it is coated, possibly using several embossing steps, until the porosity desired is achieved.

A lower cost, predecorated, substantially maintenance-free gypsum wallboard, which can justify its increased cost, relative to regular cream-faced gypsum wallboard, in home construction, particularly prefabs, is always being sought.

SUMMARY OF THE INVENTION

The present invention consists of a predecorated gypsum board paper suitable for use in making gypsum board on standard manufacturing equipment, and a wallboard made therewith having the essential maintenance-free characteristics.

In accordance with the invention, a white-faced or cream-faced gypsum board paper is first rotogravure printed, throughout its front surface, with a base coat of clear or tinted thermosetting, catalyzed, or self-cross-linking aqueous latex, having substantially through-out minutely closely spaced, minute openings or voids, which open areas may be continuous with discontinuous minute areas of base coat, or discontinuous minute areas surrounded by continuous or adjoined areas of base coat, or a combination of the two, which, following relatively instantaneous drying, is overprinted with a high binder, thermoplastic resin containing ink, which may be applied throughout any percentage desired of the total area, preferably in from 2 to 8 separate printing steps with, thus, 2 to 8 different colors or tints produced in the top decorative coating. The base coat is subsequently cured.

It is an object of the present invention to provide a novel predecorated paper for the manufacture of gypsum wallboard and a novel predecorated wallboard made therefrom.

It is a further object to provide a novel process for making a predecorated gypsum wallboard paper and, thus, a novel process for making predecorated gypsum wallboard.

It is a still further object to provide a process and resultant predecorated gypsum wallboard at a relatively low cost, having a high degree of maintenance-free characteristics.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

These and other objects and advantages of the invention will be more readily apparent when considered in relation to the preferred embodiments of the invention as set forth in the following specification.

In accordance with the invention, gypsum wallboard paper, of about 0.005 to 0.020 inch thickness, is first manufactured using known Fourdrinier or cylinder type paper machines. The quality of the predecorated gypsum board made by the invention will be, in part, dependent on the smoothness of the front surface of the face paper, with a smoothness of from about 60 to about 400 Sheffield units being satisfactory for most designs, and about 60 to about 200 Sheffield units being essential for high fidelity designs, such as wood grain patterns. The lower the Sheffield units for any paper, and thus the smoother the paper, the better it will be for use in the invention.

The porosity of the paper to be predecorated preferably has a porosity of about 25 to 70 seconds, when tested using a Gurley Densometer, in accordance with TAPPI Standards T460m-49, however less porous paper, up to 100 seconds or more, can still be used to make predecorated front paper in accordance with the invention. More porous paper, as fast as about 10 seconds, can also be successfully used. Considering porosity alone, the more porous the paper is the better for making gypsum board.

The Cobb value of the paper, tested on the front surface, in accordance with the general test outlined by TAPPI, should be no greater than 1.8 grams. The consistent brightness and color of the paper can be of importance in maintaining a consistent product, with each predecorated board of a given design matching all other boards of the same given design.

The front surface of the face paper is, first, printed, by the rotogravure process, with a plurality of closely spaced minute dots or extremely narrow, closely spaced parallel lines, when viewed through a microscope, forming a coat of a thermosetting aqueous latex emulsion having substantially throughout minutely closely spaced, minute openings or voids, which open areas may be continuous with discontinuous minute areas of base coat, or discontinuous minute areas surrounded by continuous or adjoined areas of base coat, or a combination of the two. This thermosetting aqueous latex emulsion coat may be either clear or tinted. It is preferably disposed uniformly throughout substantially all of the face paper front surface. This coat of separated minute dots or lines or the like of thermosetting aqueous latex emulsion, immediately after application, normally flows to a limited extent prior to its drying, forming a base coat, which when dried may be in the form of minute separated dots or lines or in the form of minute interconnected dots with a great plurality of openings resulting from the emulsion of the dots or lines being insufficient to completely coat and close any substantial area. These openings are spaced apart at average distances of between 0.1 inch and 0.001 inch, and preferably about 1/32 inch to about 1/320 inch, relatively uniformly throughout the base coat.

The viscosity of the thermosetting aqueous latex emulsion is important in order to be able to deposit a proper amount by a rotogravure process onto the face paper front surface. Viscosity determination, by a General Electric Zahn viscometer method, should indicate a viscosity of about 15 to about 30 seconds, when measuring the time for a measured amount of emulsion, contained in a #2 Zahn cup, to flow out through the orifice in the bottom, a test method commonly used in the ink and paint industry. Plain water, tested in a #2 Zahn cup, has a viscosity of about 15 seconds, and, thus, about 15 seconds is the minimum viscosity of a suitable thermosetting aqueous latex emulsion. The maximum permissible viscosity is that viscosity at which the emulsion can still be deposited by a rotogravure process.

Preferably the base coat is a self-reactive, cross-linking copolymer, activated by heat after having a second design coat printed over the base coat. This heat activation, to cure the base coat, can be delayed until after the paper has been used to form gypsum wallboard, at which time curing is carried out in the wallboard dryer, as the wallboard is dried, and excess water in the set gypsum core is removed. The curing forms a tough, hard, durable, non-blocking coating, from a coating which had no durability before curing.

The thermosetting latex base coat may be a self-reactive acrylic, or an acrylic-vinyl copolymer. Examples of suitable thermosetting acrylic latex emulsions include Amsco RES 3112 sold by Union Chemicals Division of Union Oil Company of California as number 8262, and a Clear Gloss Aqualure sold by Glidden Coatings and Resins Division of SCM Corporation as number 847-C-02109. Prior to use, the Clear Gloss Aqualure must be catalyzed in the ratio of one part by weight of Catalyst Converter 297-C-12128 to thirteen parts by weight of Clear Gloss Aqualure.

The base coat is applied at a rate of about one to three pounds of 30% solids emulsion per thousand square feet of paper, or about 1/4 to one pound of solids per thousand square feet of paper. This emulsion is applied to a continuously moving web, about four feet wide, of face paper, by the rotogravure process, using a chromed steel roll rotary press, printing the emulsion in the form of minute shapes minutely spaced apart substantially throughout the whole front surface of the face paper, with the exception of an uncoated edge portion at each side, of about 5/8" to 3/4" width.

If minute dots are employed, they are of a size such that there are between about 1000 and 100,000 spaced apart dots per square inch, preferably from about 3000 to 40,000 spaced apart dots per square inch, such as about 55 to 200 dots per lineal inch in each of two perpendicular directions, for example. The dots are formed by the emulsion being placed in minute holes extending into the rotogravure printing roll and deposited on the paper surface in a manner similar to rotogravure printing of ink solutions. The holes, and the resultant dots may be of any shape, circular, square, oblong, etc., so long as the holes will retain the emulsion until the paper is contacted and the emulsion will then deposit on the paper, at the desire rate of application. Typically the holes may average about 0.005 inch in diameter and between about 0.001 and 0.002 inch deep. If a pattern of narrow lines are employed, there should be about 30 to about 300 lines per inch.

As an example, the rotary press cylinder may have holes or depressions of a generally semi-spherical shape, arranged in diagonal rows, 45° in each direction from a line circumscribing the circumference of the cylinder, with 120 holes per inch in each diagonal direction, and thus 14,400 holes or depressions per square inch. The holes or depressions are separated by lands between depressions which extend in a generally zig-zag manner circumferentially around the cylinder, resulting from the diagonal arrangement of the rows of depressions, and from the narrow shallow groove adjoining depressions lying adjacent to each other in circumferential directions. This gravure print cylinder is referred to as having a QCH cell configuration in the rotogravure printing industry and is a preferred cell configuration in the present invention.

The base coat is dried, but not cured, immediately and the base-coated paper is fed to a plurality of, from about 2 to about 8, printing rolls, each of which prints a design onto the base-coated, but not cured, paper using what are referred to as high-binder durable inks. The base coat, once cured, protects the paper, and the durability of the inks protects the inks.

Each printing roll applies a portion of a design, each in different colors or different shades of a color, preferably in small blotches, i.e. small, irregular spots or marks using the high-binder inks. The high-binder inks are a mixture of pigment, a thermoplastic resin, and a solvent, all of which preferably are relatively non-reactive with the base coat.

The base-coated and printed front paper is then either fed directly to a machine for forming gypsum wallboard, or wound into a roll temporarily, to subsequently be unwound and fed to a wallboard machine. When fed to the wallboard machine, the face paper is conveyed, front surface down, and a settable gypsum aqueous slurry is disposed on the face paper back surface. A continuous web of back paper is then disposed over the gypsum slurry and the edges of the face paper are wrapped up and around the edge of the slurry, as the composite is formed into a flat thin board form.

The back paper may be of any known sultable type of gypsum board paper, preferably generally similar to the basic uncoated face paper, particularly in weight and porosity, but of lower cost paper fiber raw material, less brightness and less smoothness, these characteristics being of less importance on the gypsum board back surface.

After forming, the gypsum boards of the invention are cut into suitable lengths and conveyed through a high temperature board dryer. The base coat is cured in the board dryer, forming the very durable coating essential in predecorated wallboards. A period of about 5 minutes at 300° F. or a period of about 30 minutes at 200° F. are typical of the amount of heat required for a satisfactory cure of a preferred thermosetting base coat.

Having completed a detailed disclosure of the preferred embodiments of our invention so that those skilled in the art may practice the same, we contemplate that variations may be made without departing from the essence of the invention or the scope of the appended claims.

Claims (16)

We claim:
1. A predecorated gypsum wallboard face paper suitable for use in manufacturing gypsum wallboard, said paper comprising a continuous web of porous paper of about 0.005 to 0.020 inch thickness, said paper having a base coat of uncured reactive and curable resin applied to the front surface in a pattern of a plurality of small printed shapes spaced closely apart throughout said surface, and a colored design of high-binder inks printed over said base coat throughout any percentage desired of the total area of said paper front surface, said high-binder ink designs comprising blotches of a pigment and thermoplastic resin mixture.
2. A predecorated gypsum wallboard face paper as defined in claim 1 wherein said plurality of small printed shapes form openings through said base coat spaced apart at average distances of between about 0.1 inch and about 0.001 inch.
3. A predecorated gypsum wallboard face paper as defined in claim 1 wherein said plurality of small printed shapes form openings through said base coat spaced apart at average distances of between about 1/32 inch and about 1/320 inch.
4. A predecorated gypsum wallboard face paper as defined in claim 1 wherein said base coat is present in an amount of about 1/4 to about one pound of material per thousand square feet of paper.
5. A predecorated gypsum wallboard face paper as defined in claim 1 wherein said base coat is a clear acrylic.
6. A predecorated gypsum wallboard face paper as defined in claim 1 wherein said printed shapes are small dots with about 1,000 to about 100,000 dots per square inch.
7. A redecorated gypsum wallboard face paper as defined in claim 1 wherein said printed shapes are narrow parallel lines, with about 30 to about 300 lines per lineal inch.
8. A predecorated gypsum wallboard face paper as defined in claim 1 wherein said colored design printed over said base coat is printed in a plurality of colors and consists of a plurality of small blotches of each respective color.
9. A predecorated gypsum wallboard, comprising a set gypsum core, a back paper and a predecorated face paper, said face paper having been formed by the method comprising the steps of applying a base coat of reactive, curable resin to the front surface of a gypsum wallboard porous face paper by a rotogravure printing process, said base coat being printed on said surface in a pattern consisting of small printed shapes spaced closely apart throughout said surface and printing a colored design over said base coat throughout any percentage desired of total area of said paper front surface with high-binder inks, said high-binder inks comprising a mixture of pigment, thermoplastic resin and a solvent, all non-reactive with said base coat, said uncured reactive and curable resin having been set by the prior application of heat thereto.
10. A predecorated gypsum wallboard as defined in claim 9 wherein said plurality of small printed shapes form openings through said base coat spaced apart at average distances of between about 0.1 inch and about 0.001 inch.
11. A predecorated gypsum wallboard as defined in claim 9 wherein said plurality of small printed shapes form openings through said base coat spaced apart at average distances of between about 1/32 inch and about 1/320 inch.
12. A predecorated gypsum wallboard as defined in claim 9 wherein said base coat is present in an amount of about 1/4 to about one pound of material per thousand square feet of paper.
13. A predecorated gypsum wallboard as defined in claim 9 wherein said base coat is a clear acrylic.
14. A predecorated gypsum wallboard as defined in claim 9 wherein said printed shapes are small dots with about 1,000 to about 100,000 dots per square inch.
15. A predecorated gypsum wallboard as defined in claim 9 wherein said printed shapes are narrow parallel lines, with about 30 to about 300 lines per lineal inch.
16. A predecorated gypsum wallboard as defined in claim 9 wherein said colored designed printed over said base coat is printed in a plurality of colors and consists of a plurality of small blotches of each respective color.
US06/812,516 1984-12-13 1985-12-23 Predecorated gypsum board Expired - Lifetime US4725477A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US06/680,798 US4579610A (en) 1984-12-13 1984-12-13 Method of making predecorated gypsum board
US06/812,516 US4725477A (en) 1984-12-13 1985-12-23 Predecorated gypsum board

Applications Claiming Priority (2)

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US06/812,516 US4725477A (en) 1984-12-13 1985-12-23 Predecorated gypsum board
US07/100,803 US5055323A (en) 1984-12-13 1987-09-24 Method of making predecorated gypsum board face paper

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US07/100,803 Division US5055323A (en) 1984-12-13 1987-09-24 Method of making predecorated gypsum board face paper

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Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6012255A (en) * 1997-09-09 2000-01-11 Smid; Dennis M. Construction board having a number of marks for facilitating the installation thereof and a method for fabricating such construction board
US6387172B1 (en) 2000-04-25 2002-05-14 United States Gypsum Company Gypsum compositions and related methods
US20030084633A1 (en) * 1995-06-30 2003-05-08 Francois Zuber Method, assembly and additional coat for the construction of interior works
US20040154264A1 (en) * 2000-08-04 2004-08-12 Colbert Elizabeth A. Coated gypsum board products and method of manufacture
US20040224584A1 (en) * 2003-05-08 2004-11-11 Techfab, Llc - Anderson, Sc Facing sheet of open mesh scrim and polymer film for cement boards
US20050072104A1 (en) * 2001-10-30 2005-04-07 Schuman Thomas L. Boards comprising an array of marks to facilitate attachment
US20050227013A1 (en) * 2004-04-13 2005-10-13 Lafarge Platres Coating spray apparatus and method of using same
US20050234174A1 (en) * 2004-04-14 2005-10-20 Elizabeth Colbert Coating for wall construction
US20050229519A1 (en) * 2004-04-14 2005-10-20 Elizabeth Colbert System using a drywall board and a jointing compound
US20050246993A1 (en) * 2004-04-13 2005-11-10 Elizabeth Colbert System using a drywall board and a jointing compound
US20050252128A1 (en) * 2004-04-13 2005-11-17 Elizabeth Colbert Coating for wall construction
US20060048684A1 (en) * 2002-11-08 2006-03-09 Lafarge Platres Joint coating composition for construction elements and method for producing a structure
US20070048490A1 (en) * 2005-06-09 2007-03-01 United States Gypsum Company Low dust gypsum wallboard
US20070102237A1 (en) * 2005-11-04 2007-05-10 Usg Interiors, Inc. Acoustical gypsum board for ceiling panel
US20080090068A1 (en) * 2005-06-09 2008-04-17 United States Gypsum Company Microstructure features of gypsum wallboard made with high starch and high dispersant level
US20100239886A1 (en) * 2005-06-09 2010-09-23 United States Gypsum Company High Starch Light Weight Gypsum Wallboard
US20110195241A1 (en) * 2005-06-09 2011-08-11 United States Gypsum Company Low Weight and Density Fire-Resistant Gypsum Panel
USRE44070E1 (en) 2005-06-09 2013-03-12 United States Gypsum Company Composite light weight gypsum wallboard

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US20040216424A1 (en) * 1995-06-30 2004-11-04 Lafarge Platres Construction assembly of plaster boards and a method of assembling a plurality of plaster boards
US8151532B2 (en) 1995-06-30 2012-04-10 Lafarge Platres Construction assembly of skim coated prefabricated elements and jointing material, a kit therefor, and method of assembling the same
US20040237436A1 (en) * 1995-06-30 2004-12-02 Lafarge Platres Construction assembly of skim coated prefabricated elements and jointing material, a kit therefor, and method of assembling the same
US20030084633A1 (en) * 1995-06-30 2003-05-08 Francois Zuber Method, assembly and additional coat for the construction of interior works
US7208225B2 (en) * 1995-06-30 2007-04-24 Lafarge Platres Prefabricated plaster board
US7337587B2 (en) 1995-06-30 2008-03-04 Lafarge Platres Construction assembly of plaster boards and a method of assembling a plurality of plaster boards
US6012255A (en) * 1997-09-09 2000-01-11 Smid; Dennis M. Construction board having a number of marks for facilitating the installation thereof and a method for fabricating such construction board
US6387172B1 (en) 2000-04-25 2002-05-14 United States Gypsum Company Gypsum compositions and related methods
US6481171B2 (en) 2000-04-25 2002-11-19 United States Gypsum Company Gypsum compositions and related methods
US20040154264A1 (en) * 2000-08-04 2004-08-12 Colbert Elizabeth A. Coated gypsum board products and method of manufacture
US9404253B2 (en) 2001-10-30 2016-08-02 Huber Engineered Woods Llc Boards comprising an array of marks to facilitate attachment
US9284731B2 (en) 2001-10-30 2016-03-15 Huber Engineered Woods Llc Boards comprising an array of marks to facilitate attachment
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US7882661B2 (en) * 2001-10-30 2011-02-08 Huber Engineered Woods Llc Boards comprising an array of marks to facilitate attachment
US20050072104A1 (en) * 2001-10-30 2005-04-07 Schuman Thomas L. Boards comprising an array of marks to facilitate attachment
US8595993B2 (en) 2001-10-30 2013-12-03 Huber Engineered Woods Llc Boards comprising an array of marks to facilitate attachment
US20090229736A1 (en) * 2002-11-08 2009-09-17 Lafarge Platres Joint compound composition for building elements and method of producing a structure
US7842218B2 (en) 2002-11-08 2010-11-30 Lafarge Platres Method of producing a structure
US20060048684A1 (en) * 2002-11-08 2006-03-09 Lafarge Platres Joint coating composition for construction elements and method for producing a structure
US7594963B2 (en) 2002-11-08 2009-09-29 Lafarge Platres Joint compound composition for building elements and method of producing a structure
US20040224584A1 (en) * 2003-05-08 2004-11-11 Techfab, Llc - Anderson, Sc Facing sheet of open mesh scrim and polymer film for cement boards
US20050252128A1 (en) * 2004-04-13 2005-11-17 Elizabeth Colbert Coating for wall construction
US20050227013A1 (en) * 2004-04-13 2005-10-13 Lafarge Platres Coating spray apparatus and method of using same
US7214411B2 (en) 2004-04-13 2007-05-08 Lafarge Platres Coating spray apparatus and method of using same
US20050246993A1 (en) * 2004-04-13 2005-11-10 Elizabeth Colbert System using a drywall board and a jointing compound
US20050229519A1 (en) * 2004-04-14 2005-10-20 Elizabeth Colbert System using a drywall board and a jointing compound
US7414085B2 (en) 2004-04-14 2008-08-19 Lafarge Platres Coating for wall construction
US7469510B2 (en) 2004-04-14 2008-12-30 Lafarge Platres System using a drywall board and a jointing compound
US20080275167A1 (en) * 2004-04-14 2008-11-06 Lafarge Platres Coating for wall construction
US20050234174A1 (en) * 2004-04-14 2005-10-20 Elizabeth Colbert Coating for wall construction
US20080090068A1 (en) * 2005-06-09 2008-04-17 United States Gypsum Company Microstructure features of gypsum wallboard made with high starch and high dispersant level
US8197952B2 (en) 2005-06-09 2012-06-12 United States Gypsum Company High starch light weight gypsum wallboard
US8257489B2 (en) 2005-06-09 2012-09-04 United States Gypsum Company Slurries and methods of making light weight gypsum board
USRE44070E1 (en) 2005-06-09 2013-03-12 United States Gypsum Company Composite light weight gypsum wallboard
US8470461B2 (en) 2005-06-09 2013-06-25 United States Gypsum Company Light weight gypsum board
US9840066B2 (en) 2005-06-09 2017-12-12 United States Gypsum Company Light weight gypsum board
US20110195241A1 (en) * 2005-06-09 2011-08-11 United States Gypsum Company Low Weight and Density Fire-Resistant Gypsum Panel
US20100239886A1 (en) * 2005-06-09 2010-09-23 United States Gypsum Company High Starch Light Weight Gypsum Wallboard
US9802866B2 (en) 2005-06-09 2017-10-31 United States Gypsum Company Light weight gypsum board
US20070048490A1 (en) * 2005-06-09 2007-03-01 United States Gypsum Company Low dust gypsum wallboard
US20070102237A1 (en) * 2005-11-04 2007-05-10 Usg Interiors, Inc. Acoustical gypsum board for ceiling panel

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